Technical characteristics and types of welding machines

 

What are the types of welding machines?

 A welding unit is a mobile equipment based on an internal combustion engine that drives an electric generator. In fact, a mobile power plant that provides energy to the arc welding machine.

Scope of application of welding units

 The autonomous unit for performing welding works is a conglomerate of the platform of an autonomous welding plant with a synchronous transformer for working in the field without using permanent sources of electricity.

 Energy independence, the ability to freely move around objects without taking into account climatic conditions, the prompt solution of problems to eliminate accidents is a small part of the spectrum of demand for power plants.

 Functionally, these are un killable systems of universal purpose, having powerful protection against physical external influence and inept handling. Easy maintenance, safety systems allow you to entrust expensive equipment to medium-qualified personnel.

 The technological compartment is enclosed in a strong ventilated metal housing. The station combines two key units: an engine, and an electric generator. The power plant sets the rotation of the node generating electricity and current by means of a coupling connection.

 The power supply is consumed for the maintenance of a professional welding machine. Powerful stations are able to warm up concrete, thaw frozen soil, and service additional mechanisms. The control and monitoring devices are grouped on the control panel.

Design and device

 Structurally, the units are divided into categories:

 According to the installation type-wheeled, on a cargo platform, self-propelled with the addition of lifting mechanisms;

According to the type of power drive-diesel, gasoline;

Industrial and household;

By category of electrical installations – valve, collector.

Free access to components and mechanisms for maintenance and repair is carried out through swing doors, removable blinds. In some cases, it is planned to equip the station with additional gas cylinder equipment in isolated compartments, tools.

 [stextbox id=’warning’]Professional installations are focused on non-stop operation with periodic short-term technological interruptions.[/stextbox]

 The power supply of industrial installations varies 220/380 V. Household appliances are limited by the supply voltage of 220 V.

 Diesel engines have a reserve of power, capable of producing up to 500 kW. Gasoline-a maximum of 15 kW.

 Fundamental differences in installations:

 welding transformers;

welding rectifiers;

welding inverters;

semi-automatic equipment.

 Electric welding machine of transformer type

 Professional welding machine of a simple type. It is cumbersome due to the volume and weight of the step-down transformer, which changes the voltage to the operating optimum, and the need for forced cooling of the installation. The current strength is regulated by changing the distance between the mobile and stationary windings or by a ballast rheostat.

 Benefits of using:

 The efficiency of transformers is within 90%.

Constructive simplicity, the rarity of failures.

Easy maintenance, long-term operation.

Relative cheapness in comparison with others.

 Minuses:

 The need for highly qualified welders.

The arc stability is lower in comparison with the inverter.

Dimensions and weight.

 Rectifiers

 The device with an AC converter is the next generation of arc welding. Semiconductor valves equalize the current and conduct it in one direction. A stable arc is formed, which affects the improvement of the quality of the seam. The chokes act as filters and regulators of the electron flow.

 Advantages of rectifiers:

 Welding of non-ferrous metals and cast iron has been simplified.

The equipment has lost weight and volume.

Metal fumes and electrode splashing decreased.

The quality has increased with a lower level of qualification of operators.

 Significant disadvantages:

 Increased cost in comparison with the transformer.

The need for intensive cooling.

Vulnerability to voltage level fluctuations.

 Mobile welding machines 220 V

 An example is the family of high-frequency motorized welding units "Sever", designed for intensive use. They are capable of performing a full cycle of work on electric arc welding, cutting, and connecting rails into a whip.

 Equipped with a diesel engine with a fuel consumption of 1.1-4.5 liters / hour, an electric starter with a power of 5-66 kW and a weight of 0.13-0.92 tons, they work as single-and multi-post devices without heat loss in long-distance cables. An auxiliary generator is built in.

 Technological characteristics allow you to:

 Connect magnetized pipes.

Light the arc on the primer layer.

Cook under water.

 Unpretentious autonomous ADD-on units on the chassis

 The designers of the Uraltermosvar plant have taken the path of simplification and cheapening. The single-post installation is mounted on 2-4-wheel chassis in a solid frame with a channel strapping, covered with a casing for noise suppression, protection in bad weather. Provides energy to a professional welding machine. It is possible to connect other electrical equipment and tools.

 [stextbox id=’warning’]The manufacturer, for the sake of reliability of the equipment, excluded electronics.[/stextbox]

 Result:

 It is permissible to operate at 98% humidity.

Operating temperature range–45–+450 c.

 The diesel 4-cylinder engine is cooled by air flow, an additional measure to prevent damage to the engine. Current strength adjustment is available roughened stepwise, smooth, remote with a distance of up to 20 m. Ranges of 3-stage regulation:

 60-165 A;

150-320 A;

300-430 A.

 The DC generator ensures the stability of ignition, gorenje maintenance, elasticity of the arc. The qualitative superiority over diesel generators of the collector type is confirmed.

 Operating voltage 36-100 V. The size of the electrode is limited to Ø 6 mm.

 The unit is adapted to the hook and transportation by motor transport, tractor over rough terrain. The volume of the fuel tank is sufficient for continuous operation during the day. At negative temperatures, the fuel network warms up automatically. The working area is covered with a polypropylene waterproof tent in bad weather.

 Characteristics of welding ADD units on a single-axis trolley:

Brand Diesel Fuel consumption Current range Type of cooling Weight, dimensions

ADD-4004P 37 kW, 1800 rpm 4.4 kg / h. 60-450 A Air 1.03 t, 1.68x1, 93x2, 85 m

ADD-4001 36.8 kW, 1800 rpm 5.2 l / h 45-430 A Air 0.82 t, 1, 0x1, 3x224 m

Mobile semi-automatic machines

 Autonomous mobile stations that generate a constant or impulsive current, where welding processes are carried out in the environment of protective gases or under the flux with the automatic supply of filler wire – modern productive installations.

 The constructive complexity is adjacent to the simplicity of management. High performance, an impressive set of functions and compactness have put semi-automatic machines in the lead.

 In the field, the welder's workplace is covered with a portable awning to prevent the protective gas from blowing up by the wind. Working with filler flux wire simplifies safety measures. Manipulations on control and adjustments are carried out remotely, with a distance of up to 15 m.

 Advantages of semi-automatic machines:

 Double productivity while improving quality.

The remote control.

Soft stepless adjustments.

All-weather conditions.

Excessive backup power contributes to the connection of additional mechanisms.

 Minuses:

 Expensive consumables.

High installation cost.

 Inverter generators

 [stextbox id=’warning’]The inverter conversion of electrical signals by generators interlocked with a high-quality energy source is a professional welding inverter of an autonomous type.[/stextbox]

 The unit consists of:

 Internal combustion engine.

An alternating current generator.

An inverter converter.

Monitoring and control units.

Output connectors for 220 V.

 With the start of the engine, the sinusoidal energy of the generator follows the diode bridge for rectification, the capacitor filter smoothes the ripples to a straight line.

 Automatic adjustment to the current load generates efficiency.

The quality of the generator current.

The weight and dimensions are 2-6 times smaller with equal power.

An Antistick function that prevents the electrode from sticking.

Doubled service life and warranty.

 The MOSA GE 20 PSX diesel generator with a rated power of 18 kW weighs 650 kg.

 Variants of execution – a container, on a trolley of a 2-wheel chassis in a casing. The fuel consumption of a 4 – cylinder liquid-cooled diesel engine is 5.3 liters at a load of 100%; 4 liters/h. - at 75%; 2.7-at 50%. Dimensions: 0, 98x1, 11x1, 72 m.

 [stextbox id=’info’]In addition to the main purpose, the generator is used for power supply of industrial and residential facilities.[/stextbox]

 Electricity parameters:

 Voltage – 230/400 V.

Current – 29/32 A.

 Two-post semi-automatic welding generator

 Handwashing DGW500DM/EURA has concentrated multi-mode devices in one case to meet any need without re configuring the equipment:

 It cooks with a metal electrode with a coating of Ø 1.6–8 mm.

A non-melting tungsten electrode in a protective environment with automatic gas supply.

Semi-automatic welding with active gas protection.

Welding with powder flux wire.

Like a mobile power plant.

 Independence of welding posts with a feed for each 280 A. The function of facilitating hot start ignition of VRD, soft adjustment of the dynamics of the process, a simple transition to a different type of electrode. The no-load voltage of 85 V eliminates the breakage of the arc when its length changes.

 There are 14 sockets for connecting various energy consumers for preparatory work and seam processing. Switching to idle mode leads to an immediate loss of speed and fuel consumption.

 The digital instrument panel for monitoring and control allows you to perform preset modes without subsequent correction. There is no need to organize noise absorption within localities – the sound threshold is 57 dB.

Each workplace is equipped with an independent remote control. The diesel engine is started by an electric starter, consumes 3.8 l/h of fuel. The generator outputs a voltage of 230/380 V, current up to 500A. The unit fits into a modest weight of 613 kg.

For home and garden

 Construction and installation works of small volumes, the creation of your own repair and production business require good technical support. Sometimes the supply of the power line is expensive and long.

 In this case, the gasoline welding unit will turn into a working tool and a mobile power plant for lighting and ensuring the penetrability of the power tool until better times.

 Initially, it is planned to use the combine in two modes: an electric welding machine and a domestic current generator. The production of direct current in the range of 160-50 A ensures the successful operation of the welder with an electrode up to Ø 4 mm.

 the 2-stroke gasoline engine is started by a manual cord starter. The synchronous generator generates a 1-phase voltage of 230 V at a consumption of 2 liters of gasoline per hour. The nominal power is 4.7-5.2 kW.

 The device belongs to the portable class – its own weight is 28 kg. The dimensions of 0, 3x0, 41x0, 53 m allow you to put it on a regular shopping cart for ease of movement.

 Homemade crafts live and thrive

 The creation of a personal energy independent unit based on a purchased 4 kW generator and a homemade or ready-made welding machine is justified and expedient. The idea of mobility and autonomy should be supplemented:

 Install additionally for the expansion generator function 1-2 sockets;

 Enclose the equipment in all-weather removable cases made of plastic or metal;

Organize additional cooling by a fan;

Put the block on the wheels.